F75 F90

OWNERS MANUAL

U.S.A.Edition LIT-18626-07-12 6D6-28199-13
U6D613E0.book Page 1 Thursday, March 2, 2006 11:28 AM

ZMU01690

Read this owners manual carefully before operating your outboard motor.
Important manual information

EMU31280

To the owner
Thank you for choosing a Yamaha outboard motor. This Owners Manual contains information needed for proper operation, maintenance and care. A thorough understanding of these simple instructions will help you obtain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owners Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

EWM00780

your machine and this manual. If there is any question concerning this manual, please consult your Yamaha dealer.
The F75TR, F90TR and the standard accessories are used as a base for the explanations and illustrations in this manual. Therefore some items may not apply to every model.

EMU25110

WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor.

ECM00700

F75, F90 OWNERS MANUAL 2006 by Yamaha Motor Corporation, USA 1st edition, February 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in Japan P/N LIT-18626-07-12

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
A NOTE provides key information to make procedures easier or clearer. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between

Table of contents

General information. 1 Identification numbers record.. 1
Outboard motor serial number. 1 Key number.. 1 Trim tab with anode. Tilt support lever for power trim and tilt or hydro tilt model. Top cowling lock lever (pull up type).. Flushing device.. Water separator.. Digital tachometer.. Low oil pressure warning indicator. Overheat warning indicator (digital type).. Speedometer (digital type).. Trim meter (digital type). Hour meter (digital type). Trip meter... Clock.. Fuel gauge.. Fuel warning indicator.. Low battery voltage warning indicator.. Command link multifunction meters.. Tachometer unit. Speed & fuel meter unit.. Speedometer unit.. Fuel management meter. 30
Emission control information. 1
North American models.. 1 Star labels.. 2
Safety information.. 3 Important labels. 4

Warning labels. 4

Basic boating rules (Rules of the road).. 5
Steering and sailing rules and sound signals.. 5 Rules when encountering vessels. 5 Other special situations.. 6

Fueling instructions.. 8

Gasoline.. 9 Engine oil.. 9

Battery requirement.. 10

Battery specifications.. 10
Propeller selection.. 10 Start-in-gear protection.. 11 Basic components. 12 Main components. 12
Remote control.. Remote control lever. Neutral interlock trigger.. Neutral throttle lever.. Tiller handle.. Gear shift lever.. Throttle grip.. Throttle indicator. Throttle friction adjuster.. Engine stop lanyard switch.. Engine stop button.. Main switch.. Power trim and tilt switch on remote control or tiller handle.. Power trim and tilt switch on bottom engine cowling.. Variable trolling RPM switches. 18

Warning system.. 30

Overheat warning.. 30 Low oil pressure warning. 31
Operation... 32 Installation.. 32
Mounting the outboard motor. 32

Breaking in engine. 33

Procedure for 4-stroke models. 33

Preoperation checks. 33

Fuel.. Controls.. Engine... Checking the engine oil level. 34 34

Filling fuel.. 34

Ring Free Fuel Additive.. 35

Operating engine. 35

Feeding fuel.. 35
U6D613E0.book Page 2 Thursday, March 2, 2006 11:28 AM

Starting engine.. 36

Warming up engine.. 38
Electric start models.. 38

Shifting.. 39

Forward (tiller handle and remote control models).. 39 Reverse (automatic reverse lock and power trim and tilt models).. 40

Trolling.. 40

Adjusting trolling speed.. 40

Stopping engine.. 41

Procedure... 41
Trimming outboard motor. 41
Adjusting trim angle. 42 Adjusting boat trim.. 43

Tilting up and down.. 43

Procedure for tilting up (power trim and tilt models / power tilt models)... 44 Procedure for tilting down (power trim and tilt models / power tilt models)... 45
Greasing.. Cleaning and adjusting spark plug. Checking fuel system.. Changing engine oil. Checking wiring and connectors. Exhaust leakage. Water leakage.. Engine oil leakage.. Checking power trim and tilt / power tilt system.. Checking propeller.. Removing the propeller.. Installing the Propeller.. Changing gear oil.. Inspecting and replacing anode(s). Checking battery (for electric start models)... Connecting the battery. Disconnecting the battery.. Checking top cowling.. Coating the boat bottom.
Cruising in shallow water. 46
Power trim and tilt models / power tilt models.. 46
Trouble Recovery.. 66 Troubleshooting.. 66 Temporary action in emergency. 69
Impact damage.. Replacing fuse.. Power trim and tilt / power tilt will not operate.. Water separator warning indicator blinks while cruising.. Starter will not operate. Emergency starting engine.. 72 73
Cruising in other conditions. 47 Maintenance.. 48 Specifications.. 48 Transporting and storing outboard motor.. 49
Storing outboard motor. Procedure... Lubrication.. Cleaning and anticorrosion measures.. Battery care.. Flushing power unit. Cleaning the outboard motor. Checking painted surface of motor. 53 53

Treatment of submerged motor. 74

Procedure... 74

Periodic maintenance.. 53
Replacement parts.. 53 Maintenance chart.. 54 Maintenance chart (additional). 55
U6D613E0.book Page 3 Thursday, March 2, 2006 11:28 AM
Consumer information.. 75 Important warranty information for U.S.A. and Canada.. 75 YAMAHA MOTOR CORPORATION, U.S.A. FOUR-STROKE OUTBOARD MOTOR THREE-YEAR LIMITED WARRANTY.. 77 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA. 79

General information

EMU25170
Identification numbers record

EMU25183

Outboard motor serial number
The outboard motor serial number is stamped on the label attached to the port side of the clamp bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is stolen.

1. Key number

EMU25221
Emission control information

EMU25230

North American models
This engine conforms to U.S. Environmental Protection Agency (EPA) regulations for marine SI engines. See the label affixed to your engine for details.

EMU31560

ZMU04214
1. Outboard motor serial number location
Approval label of emission control certificate This label is attached to the bottom cowling. New Technology; (4-stroke) MFI

EMU25190

Key number
If a main key switch is equipped with the motor, the key identification number is stamped on your key as shown in the illustration. Record this number in the space provided for reference in case you need a new key.

ZMU04217

1. Approval label location

EMU25262

1. Star labels location

EMU25280

Manufactured date label This label is attached to the clamp bracket or the swivel bracket.
One StarLow Emission The one-star label identifies engines that meet the Air Resources Boards 2001 exhaust emission standards. Engines meeting these standards have 75% lower emissions than conventional carbureted two-stroke engines. These engines are equivalent to the U.S. EPAs 2006 standards for marine engines.

ZMU04218

1. Manufactured date label location

Manufactured:

EMU25290

ZMU01702

ZMU04346

EMU25272

Star labels
Your outboard motor is labeled with a California Air Resources Board (CARB) star label. See below for a description of your particular label.
Two StarsVery Low Emission The two-star label identifies engines that meet the Air Resources Boards 2004 exhaust emission standards. Engines meeting these standards have 20% lower emissions than One Star-Low-Emission engines.
the rated horsepower capacity of the boat. If the rated horsepower capacity of the boat is unknown, consult the dealer or boat manufacturer. Do not modify the outboard. Modifications could make the motor unfit or unsafe to use. Incorrect propeller selection and incorrect use may not only cause engine damage, but also adversely affect fuel consumption. Consult your dealer for correct use. Never operate after drinking alcohol or taking drugs. About 50% of all boating fatalities involve intoxication. Have an approved personal flotation device (PFD) on board for every occupant. It is a good idea to wear a PFD whenever boating. At a minimum, children and non-swimmers should always wear PFDs, and everyone should wear PFDs when there are potentially hazardous boating conditions. Gasoline is highly flammable, and its vapors are flammable and explosive. Handle and store gasoline carefully. Make sure there are no gas fumes or leaking fuel before starting the engine. This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets. Check throttle, shift, and steering for proper operation before starting the engine. Attach the engine stop switch lanyard cord to a secure place on your clothing, or your arm or leg while operating. If you accidentally leave the helm, the cord will pull from the switch, stopping the engine.

ZMU01703

EMU25300
Three StarsUltra Low Emission The three-star label identifies engines that meet the Air Resources Boards 2008 exhaust emission standards. Engines meeting these standards have 65% lower emissions than One Star-Low-Emission engines.

ZMU01704

EMU25362

Safety information

Before mounting or operating the outboard motor, read this entire manual. Reading it should give you an understanding of the motor and its operation. Before operating the boat, read any owners or operators manuals supplied with it and all labels. Be sure you understand each item before operating. Do not overpower the boat with this outboard motor. Overpowering the boat could result in loss of control. The rated power of the outboard should be equal to or less than
U6D613E0.book Page 4 Thursday, March 2, 2006 11:28 AM
Know the marine laws and regulations where you will be boatingand obey them. For basic boating rules, see Rules of the road on page 5. G Stay informed about the weather. Check weather forecasts before boating. Avoid boating in hazardous weather. G Tell someone where you are going: leave a Float Plan with a responsible person. Be sure to cancel the Float Plan when you return. G Use common sense and good judgment when boating. Know your abilities, and be sure you understand how your boat handles under the different boating conditions you may encounter. Operate within your limits, and the limits of your boat. Always operate at safe speeds, and keep a careful watch for obstacles and other traffic. G Always watch carefully for swimmers during the engine operation. G Stay away from swimming areas. G When a swimmer is in the water near you shift into neutral and shut off the engine. G Do not illegally discard empty containers used to replace or replenish oil. For the correct processing of empty containers, consult the dealer where you purchased the oil. G When replacing oils used to lubricate the product (engine or gear oil), be sure to wipe away any spilt oil. Never pour oil without using a funnel or similar device. If necessary, verify the necessary replacement procedure with the dealer. G Never illegally discard (dump) the product. Yamaha recommends consulting the dealer on discarding the product. Be informed about boating safety. Additional publications and information can be obtained from many organizations, including the following:
United States Coast Guard Consumer Affairs Staff (G-BC) Office of Boating, Public, and Consumer Affairs U.S. Coast Guard Headquarters Washington, D.C. 20593-0001 Boating Safety Hotline: 1-800-368-5647 National Marine Manufacturers Association (NMMA) 401 N. Michigan Ave. Chicago, Il 60611 Marine Retailers Association of America 155 N. Michigan Ave. Chicago, Il 60601

EMU25382

Important labels

EMU25395

Warning labels

EMU25401

ZMU05418

1. Set button 2. Mode button

1. 2. 3. 4. 5. 6. 7. 8.

6. 7. 8. 9.
Tachometer Trim meter Multifunction display Water detection warning indicator Engine trouble warning/maintenance indicator Cooling water pressure Oil pressure (4-stroke models) Cooling water/engine temperature Battery voltage

ZMU05416

Tachometer Trim meter Multifunction display Cooling water pressure Cooling water/engine temperature Water detection warning indicator Battery voltage Oil pressure (4-stroke models)
The tachometer unit shows various kinds of information according to the setting made using the (set) and (mode) buttons. For details, see the attached operation manual. Preoperation checks Place the gear shift lever in neutral and turn the main switch to (on). After all the displays come on and the total hour display comes on, the gauge will change to normal operation. If the buzzer sounds and the water separator warning indicator blinks, consult your Yamaha dealer immediately.

ZMU05417

To stop the buzzer, press the (mode) button.

(set) or

U6D613E0.book Page 26 Thursday, March 2, 2006 11:28 AM
Low oil pressure warning When the engine oil pressure drops too low, the low oil pressure warning indicator will start to blink, and the engine speed will automatically decrease to about 2000 r/min. Overheat warning If the engine temperature rises too high while cruising, the overheat warning indicator will start to blink. The engine speed will automatically decrease to about 2000 r/min.

ZMU05430

ZMU05421

ZMU05431

ZMU05422
Stop the engine immediately if the buzzer sounds and the low oil pressure warning indicator blinks. Check the engine oil quantity and replenish oil if necessary. If the warning device has activated while the appropriate engine oil quantity is maintained, consult your Yamaha dealer.

ECM01600

Stop the engine immediately if the buzzer sounds and the overheat warning device has activated. Check the cooling water inlet for clogging.

ECM01590

Do not continue to run the engine if the low oil pressure warning device has activated. Serious engine damage will occur.
Do not continue to run the engine if the overheat warning indicator blinks. Serious engine damage will occur. Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected.

Before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstructions. Be sure there are no swimmers in the water near you. When the air vent screw is loosened, gasoline vapor will be released. Gasoline is highly flammable, and its vapors are flammable and explosive. Refrain from smoking, and keep away from open flames and sparks while loosening the air vent screw. This product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which could cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets. If there is an air vent screw on the fuel tank cap, loosen it 2 or 3 turns. If there is a fuel joint or a fuel cock on the boat, firmly connect the fuel line to the joint or open the fuel cock. Squeeze the primer pump, with the arrow pointing up, until you feel it become firm.
U6D613E0.book Page 36 Thursday, March 2, 2006 11:28 AM

1. Arrow

EMU27490
Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard where it could become entangled, preventing it from functioning. Avoid accidentally pulling the lanyard during normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward.

Starting engine

EMU27592
Electric start / prime start models 1. Place the gear shift lever in neutral.
Place the throttle grip in the (start) position. After the engine starts, return the throttle to the fully closed position.
The start-in-gear protection device prevents the engine from starting except when in neutral. 2. Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg. Then install the lock plate on the other end of the lanyard into the engine stop switch.
Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating.
(start), Turn the main switch to and hold it for a maximum of 5 seconds.
U6D613E0.book Page 37 Thursday, March 2, 2006 11:28 AM
The start-in-gear protection device prevents the engine from starting except when in neutral.
Immediately after the engine starts, release the main switch and allow it to return to (on).

ECM00191

Never turn the main switch to (start) while the engine is running. Do not keep the starter motor turning for more than 5 seconds. If the starter motor is turned continuously for more than 5 seconds, the battery will be quickly discharged, thus making it impossible to start the engine. The starter can also be damaged. If the engine will not start after 5 seconds of cranking, return the main switch to (on), wait 10 seconds, then crank the engine again.

Bow Down Too much trim-in causes the boat to plow through the water, decreasing fuel economy and making it hard to increase speed. Operating with excessive trim-in at higher speeds also makes the boat unstable. Resistance at the bow is greatly increased, heightening the danger of bow steering and making operation difficult and dangerous.
Bow Up Too much trim-out puts the bow of the boat too high in the water. Performance and economy are decreased because the hull of the boat is pushing the water and there is more air drag. Excessive trim-out can also cause the propeller to ventilate, which reduces performance further, and the boat may porpoise (hop in the water), which could throw the operator and passengers overboard.
Depending on the type of boat, the outboard motor trim angle may have little effect on the trim of the boat when operating.

EMU27933

Tilting up and down
If the engine will be stopped for some time or if the boat is moored in shallows, the outboard motor should be tilted up to protect the propeller and casing from damage by collision with obstructions, and also to reduce salt corrosion.
U6D613E0.book Page 44 Thursday, March 2, 2006 11:28 AM

EWM00220

Be sure all people are clear of the outboard motor when tilting up and down, also be careful not to pinch any body parts between the drive unit and engine bracket.

EWM00250

Leaking fuel is a fire hazard. If there is a fuel joint on the outboard motor, disconnect the fuel line or close the fuel cock if the engine will be tilted for more than a few minutes. Otherwise fuel may leak.

ECM00241

Disconnect the fuel line from the outboard motor or close the fuel cock. Press the power trim and tilt switch / power tilt switch (up) until the outboard motor has tilted up completely.
Before tilting the outboard motor, stop the engine by following the procedure on page 41. Never tilt the outboard motor while the engine is running. Severe damage from overheating can result. Do not tilt up the engine by pushing the tiller handle (if equipped) because this could break the handle.

EMU28007

Procedure for tilting up (power trim and tilt models / power tilt models)
1. Place the remote control lever / gear shift lever in neutral.

ZMU03196

U6D613E0.book Page 45 Thursday, March 2, 2006 11:28 AM

ECM00250

Be sure to retract the trim rods completely during mooring. This protects the rods from marine growth and corrosion which could damage the power trim and tilt mechanism.

EMU28055

ZMU04232
Procedure for tilting down (power trim and tilt models / power tilt models)
1. Push the power trim and tilt switch / power tilt switch (up) until the outboard motor is supported by the tilt rod and the tilt support lever / tilt support knob becomes free. Release the tilt support lever or pull out the tilt support knob.

Push the tilt support knob into the clamp bracket or pull the tilt support lever toward you to support the engine.

EWM00260

After tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever. Otherwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit loses pressure. 5. Models equipped with trim rods: Once the outboard motor is supported with the tilt support lever, press the power trim and tilt switch / power tilt switch (down) to retract the trim rods.
Push the power trim and tilt switch / power tilt switch (down) to lower the outboard motor to the desired position.

ZMU01936

U6D613E0.book Page 46 Thursday, March 2, 2006 11:28 AM
ting up for and cruising in shallow water. Otherwise severe damage from overheating can result.

EMU28185

Procedure for power trim and tilt / power tilt models 1. Place the remote control lever / gear shift lever in neutral.

ZMU04255

EMU28060
Cruising in shallow water
The outboard motor can be tilted up partially to allow operation in shallow water.

EMU28090

Power trim and tilt models / power tilt models

EWM00660

Place the gear shift in neutral before setting up for shallow water cruising. Return the outboard motor to its normal position as soon as the boat is back in deeper water.
Slightly tilt the outboard motor up to the desired position using the power trim and tilt switch / power tilt switch.

ECM00260

Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set-
U6D613E0.book Page 47 Thursday, March 2, 2006 11:28 AM
3. To return the outboard motor to the normal running position, press the power trim and tilt switch / power tilt switch and slowly tilt the outboard motor down.

EMU28192

Cruising in other conditions
Cruising in salt water After operating in salt water, flush the cooling water passages with fresh water to prevent them from becoming clogged with salt deposits.
For cooling system flushing instructions, see page 49. Cruising in turbid water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (not available for some models) if you use the outboard motor in turbid or muddy water conditions.

EMU28222

the normal running position, use an additional support device to secure it in the tilt position. The outboard motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the outboard motor in the tilt position using a motor support device such as a transom saver bar. Consult your Yamaha dealer for further details.

EMU30061

Transporting and storing outboard motor

EWM00690

Storing outboard motor
When storing your Yamaha outboard motor for prolonged periods of time (2 months or longer), several important procedures must be performed to prevent excessive damage. It is advisable to have your outboard motor serviced by an authorized Yamaha dealer prior to storage. However, you, the owner, with a minimum of tools, can perform the following procedures.

ECM01360

Leaking fuel is a fire hazard. When transporting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking. USE CARE when transporting fuel tank, whether in a boat or car. DO NOT fill fuel container to maximum capacity. Gasoline will expand considerably as it warms up and can build up pressure in the fuel container. This can cause fuel leakage and a potential fire hazard.

EWM00700

Never get under the lower unit while it is tilted, even if a motor support bar is used. Severe injury could occur if the outboard motor accidentally falls.

ECM00660

Do not use the tilt support lever or knob when trailering the boat. The outboard motor could shake loose from the tilt support and fall. If the motor cannot be trailered in
To prevent problems which can be caused by oil entering the cylinder from the sump, keep the outboard motor in the attitude shown when transporting and storing it. Do not store or transport the outboard motor on its side (not upright). Do not place the outboard motor on its side before the cooling water has drained from it completely, otherwise water may enter the cylinder through the exhaust port and cause engine trouble. Store the outboard motor in a dry, wellventilated place, not in direct sunlight.
U6D613E0.book Page 50 Thursday, March 2, 2006 11:28 AM

ECM00310

Avoid running the outboard motor at high speed while on the flushing attachment, otherwise overheating could occur.

ZMU03659

EMU28303

EMU30001

Flushing with the flushing attachment 1. Wash the outboard motor body using fresh water. For further information, see page 53. 2. Fill the fuel tank with fresh fuel and add one ounce of Yamaha Fuel Conditioner and Stabilizer (Part No. LUB-FUELC-1200) to each gallon of fuel.

EMU28910

Actions 500 hours (2.5 years) Replacement Inspection / adjustment Replacement Replacement Inspection / replacement 1000 hours (5 years)
When using lead or high-sulfur gasoline, inspecting valve clearance may be required more frequently than every 500 hours.
U6D613E0.book Page 56 Thursday, March 2, 2006 11:28 AM

EMU28931

Greasing
Yamaha marine grease (Water resistant grease)

ZMU04266

EMU28952
Cleaning and adjusting spark plug

EWM00560

When removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire. The spark plug is an important engine component and is easy to inspect. The condition of the spark plug can indicate something about the condition of the engine. For example, if the center electrode porcelain is very white, this could indicate an intake air leak or carburetion problem in that cylinder. Do not attempt to diagnose any problems yourself. Instead, take
the outboard motor to a Yamaha dealer. You should periodically remove and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode. If electrode erosion becomes excessive, or if carbon and other deposits are excessive, you should replace the spark plug with another of the correct type. Standard spark plug: LFR5A-11 Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification if necessary.
U6D613E0.book Page 57 Thursday, March 2, 2006 11:28 AM

EWM00910

Leaking fuel can result in fire or explosion. G Check for fuel leakage regularly. G If any fuel leakage is found, the fuel system must be repaired by a qualified mechanic. Improper repairs can make the outboard unsafe to operate. Check the fuel lines for leaks, crack, or malfunction. If a problem is found, your Yamaha dealer or other qualified mechanic should repair it immediately.
1. Spark plug gap 2. Spark plug part number 3. Spark plug I.D. mark (NGK)
Spark plug gap: 1.01.1 mm (0.0390.043 in) When fitting the plug, always clean the gasket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque. Spark plug torque: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m)

ZMU04244

1. Tilt rod
U6D613E0.book Page 61 Thursday, March 2, 2006 11:28 AM
If the shear pin equipped: it is designed to break if the propeller hits a hard underwater obstacle to help protect the propeller and drive mechanism. The propeller will then spin freely on the shaft. If this happens, the shear pin must be replaced.

EMU30660

ZMU04262

Removing the propeller

EMU29194
Spline models 1. Straighten the cotter pin and pull it out using a pair of pliers. 2. Remove the propeller nut, washer, and spacer (if equipped).

ZMU01897

Checkpoints G Check each of the propeller blades for wear, erosion from cavitation or ventilation, or other damage. G Check the propeller shaft for damage. G Check the splines / shear pin for wear or damage. G Check for fish line tangled around the propeller shaft.
1. 2. 3. 4. 5. 6. Cotter pin Propeller nut Washer Spacer Propeller Thrust washer

ZMU03228

Remove the propeller and thrust washer.

EMU30670

Installing the Propeller

EMU29231

Spline models

ECM00340

Check the propeller shaft oil seal for damage.
Be sure to install the thrust washer before installing the propeller, otherwise the lower case and propeller boss could be damaged.
U6D613E0.book Page 62 Thursday, March 2, 2006 11:28 AM
Be sure to use a new cotter pin and bend the ends over securely. Otherwise the propeller could come off during operation and be lost. Apply Yamaha marine grease or a corrosion resistant grease to the propeller shaft. Install the spacer (if equipped), thrust washer, and propeller on the propeller shaft. Install the spacer (if equipped) and the washer. Tighten the propeller nut to the specified torque. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends.
Never get under the lower unit while it is tilted, even when the tilt support lever or knob is locked. Severe injury could occur if the outboard motor accidentally falls. Tilt the outboard motor so that the gear oil drain screw is at the lowest point possible. Place a suitable container under the gear case. Remove the gear oil drain screw and gasket.

ZMU03273

1. Gear oil drain screw 2. Oil level plug

ZMU02063

If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, tighten the nut further to align it with the hole.

EMU29282

If a magnetic gear oil drain screw is equipped, remove all metal particles from the screw before installing it. Always use new gaskets. Do not reuse the removed gaskets. Remove the oil level plug and gasket to allow the oil to drain completely.

Changing gear oil

EWM00800

ECM00710

Inspect the used oil after it has been drained. If the oil is milky, water is getting into the gear case which can cause gear damage. Consult a Yamaha dealer for repair of the lower unit seals.
Be sure the outboard motor is securely fastened to the transom or a stable stand. You could be severely injured if the outboard motor falls on you.
U6D613E0.book Page 63 Thursday, March 2, 2006 11:28 AM

ECM00720

For disposal of used oil, consult your Yamaha dealer. 5. With the outboard motor in a vertical position, and using a flexible or pressurized filling device, inject the gear oil into the gear oil drain screw hole. Recommended gear oil: Hypoid gear oil SAE#90 Gear oil quantity: 670.0 cm (22.65 US oz) (23.63 Imp.oz)
Do not paint anodes, as this would render them ineffective.
Inspect ground leads attached to external anodes on equipped models. Consult a Yamaha dealer for inspection and replacement of internal anodes attached to the power unit.

ZMU03274

Put a new gasket on the oil level plug. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. Put a new gasket on the gear oil drain screw. Insert and tighten the gear oil drain screw.

EMU29320

ZMU04245

EMU29312

Inspecting and replacing anode(s)
Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.
Checking battery (for electric start models)
Battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive measures:
U6D613E0.book Page 64 Thursday, March 2, 2006 11:28 AM
Avoid bodily contact with electrolytic fluid as it can cause severe burns or permanent eye injury. G Wear protective eye gear when handling or working near batteries. Antidote (EXTERNAL): G SKIN - Flush with water. G EYES - Flush with water for 15 minutes and get immediate medical attention. Antidote (INTERNAL): G Drink large quantities of water or milk followed by milk of magnesia, beaten egg, or vegetable oil. Get immediate medical attention. Batteries also generate explosive hydrogen gas; therefore, you should always follow these preventive measures: G Charge batteries in a well-ventilated area. G Keep batteries away from fire, sparks, or open flames (for example: welding equipment, lighted cigarettes, and so on.) G DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN.

ECM00360

Always keep the battery in a good state of charge. Installing a voltmeter will help you monitor your battery. If you will not use the boat for a month or more, remove the battery from the boat and store it in a cool, dark place. Completely recharge the battery before using it. If the battery will be stored for longer than a month, check the specific gravity of the fluid at least once a month and recharge the battery when it is low.
Consult a Yamaha dealer when charging or re-charging batteries.

EMU29331

Connecting the battery

EWM00570

Mount the battery holder securely in a dry, well-ventilated, vibration-free location in the boat. Install a fully charged battery in the holder.

ECM01121

A poorly maintained battery will quickly deteriorate. Ordinary tap water contains minerals harmful to a battery, and should not be used for topping up. Check the electrolyte level at least once a month. Fill to the manufacturers recommended level when necessary. Top up only with distilled water (or pure de-ionized water suitable to use in batteries).
Make sure the main switch (on applicable models) is (off) before working on the battery. Reversal of the battery cables will damage the electrical parts.
U6D613E0.book Page 65 Thursday, March 2, 2006 11:28 AM
Connect the red battery cable first when installing the battery and disconnect the black battery cable first when removing it. Otherwise, the electrical parts can be damaged. The electrical contacts of the battery and cables must be clean and properly connected, or the battery will not start the engine.

EMU29400

Connect the red battery cable to the POSITIVE (+) terminal first. Then connect the black battery cable to the NEGATIVE (-) terminal.

Coating the boat bottom

A clean hull improves boat performance. The boat bottom should be kept as clean of marine growth as possible. If necessary, the boat bottom can be coated with an anti-fouling paint approved for your area to inhibit marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion.
1. Red cable 2. Black cable 3. Battery

EMU29370

Disconnecting the battery
Disconnect the BLACK cable from the NEGATIVE (-) terminal first. Then disconnect the RED cable from the POSITIVE (+) terminal.

Bulletiin # M-0409-2 April 2009
NewF75, F80, F90, F100 Pistons Product Yamaha

Marine

All piston are engineered for todays harsh marine environment and have the features you have come to expect that only Wiseco can deliver including:
Skirt Coated- Designed to reduce friction with quieter operation. Matched and balanced to factory weights for individual replacements. Reamed wrist pin hole provides a perfect geometrical surface. List Price (USA): $100.00
Bore Size (mm) 79.00 79.50

Part No.

Repl. Ring Part No. 7900XX 7950XX

Yamaha F75 F80 F90 F100

2005 & up 1999-& up 1999-02

3208PS 3208P2

Repl. WristPin Part No. S524
Repl. Circlip Part No. CW18
Copyright 2009 Wiseco Piston Co., Inc. 7201 Industrial Park Blvd. Mentor, OH 44060-5396 440-951-6600 Fax: 440-951-6606 www.wiseco.com